EP3051673B1 - Rotating rectifiers with nested diodes - Google Patents
Rotating rectifiers with nested diodes Download PDFInfo
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- EP3051673B1 EP3051673B1 EP16153948.1A EP16153948A EP3051673B1 EP 3051673 B1 EP3051673 B1 EP 3051673B1 EP 16153948 A EP16153948 A EP 16153948A EP 3051673 B1 EP3051673 B1 EP 3051673B1
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- Prior art keywords
- diode
- rectifier
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- recited
- transfer tube
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- 230000004323 axial length Effects 0.000 claims description 9
- 230000004888 barrier function Effects 0.000 claims description 5
- 239000003921 oil Substances 0.000 description 14
- 239000002826 coolant Substances 0.000 description 12
- 239000000314 lubricant Substances 0.000 description 7
- 239000012530 fluid Substances 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 238000005461 lubrication Methods 0.000 description 4
- 238000009825 accumulation Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 238000004891 communication Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 230000003068 static effect Effects 0.000 description 3
- 230000009471 action Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010705 motor oil Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/04—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for rectification
- H02K11/042—Rectifiers associated with rotating parts, e.g. rotor cores or rotary shafts
Definitions
- the present disclosure relates to electrical machines, and more particularly to synchronous machines like electrical machine generators.
- Direct drive generators and integrated drive generators are commonly used of aircraft to convert mechanical energy into electrical power.
- Direct drive generators are generally connected to an aircraft engine directly, without a gearbox or transmission assembly, and may supply variable frequency alternating current (AC) electrical power to an aircraft.
- Integrated drive generators typically connect to aircraft engine through a continuously variable transmission such as a constant speed drive.
- the continuously variable transmission receives rotational energy from the engine having a variable speed, converts the variable speed rotational energy into constant speed rotational energy, and applies the constant speed rotational energy to the integrated drive generator, the integrated drive generator thereby producing constant frequency AC electrical power.
- Both direct drive generators and integrated drive generators may include a diode pack operatively associated with a rotor of the generator assembly.
- a rectifier includes a diode with an anode face and an opposed cathode face that are both angled in relation to a rotation axis of the diode.
- a first diode plate overlays the diode anode face.
- a second diode plate overlays the diode cathode face.
- the first and second diode plates are nested with one another such that portions of the diode plates axially overlap one another along a length of the diode rotation axis.
- Each diode plate includes a body angled with respect to the rotation axis and having an axially extending key segment. The key segment having an axial length that is greater than an axial height of the diode.
- an oil transfer tube bushing can be axially disposed along the rotation axis.
- An end of the oil transfer tube bushing can be electrically connected to the diode through the first diode for grounding the diode through the oil transfer tube bushing.
- the key segments can be rotationally offset from one another about the rotation axis.
- a diode retainer can be axially disposed between the first and second diode plates such that the diode retainer circumferentially surrounds the diode.
- the diode retainer can define a keyway on its outer periphery, and a key segment of the second diode plate can seat in the diode retainer keyway.
- the diode retainer can define barrier walls adjacent to the keyway that electrically insulate the diode plates from one another in the radial direction.
- the diode retainer can define a central diode aperture bounded by a plurality of diode surfaces such that the diode and diode retainer share a common axial position.
- the diode retainer can define a plurality of flow apertures that bound the central diode aperture. Circumferentially adjacent flow apertures can be separated by one of the diode surfaces.
- the diode can be a first diode
- the rectifier can include a plurality of such diodes, for example six diodes, axially stacked in relation to one another.
- the rectifier can also include a plurality of diode plates, for example five diode plates, and each of the diode plates can be axially stacked between axially adjacent diodes and nested with an axially adjacent diode plate.
- the diodes and diode plates can form a diode pack with an axial length
- the rectifier can further include a diode pivot extending along the rotation axis and having an axial length greater than the length of the diode pack.
- a generator includes a rotor shaft with a rectifier cavity, a rectifier as described above seated in the rectifier cavity, and a transfer tube in fluid communication with the rectifier.
- the rotor shaft is rotatable about the rectifier rotation axis.
- the transfer tube extends axially along the rotation axis and is connected electrically to the rectifier through the first diode plate.
- the rectifier can include a transfer tube bushing seated between the first diode plate and the transfer tube.
- the transfer tube bushing can be fixed relative to the first diode plate and rotatable relative to the transfer tube for grounding the rectifier with the rotor shaft.
- a generator comprising a rotor shaft defining a rotation axis, a rectifier circuit fixed in relation to the rotor shaft, including a diode with anode and cathode faces angled relative to the rotation axis, a first diode plate overlaying the anode face of the diode, and a second diode plate overlaying the cathode face of the diode.
- the first and second diode plates are nested with one another such that portions of the first and second diode plates axially overlap along the rotation axis.
- An oil transfer tube extends along the rotation axis and is electrically connected to the first diode plate, and an oil transfer tube bushing is coupled between the first diode plate and the oil transfer tube.
- the oil transfer tube bushing is fixed in relation to the first diode plate and rotatable in relation to the oil transfer tube for grounding the diode through the rotor shaft.
- Fig. 1 a partial view of an exemplary embodiment of a rectifier in accordance with the disclosure is shown in Fig. 1 and is designated generally by reference character 100.
- the systems and methods described herein can be for electrical generators, such as aircraft main engine and auxiliary power unit generators.
- Rectifier 100 includes a housing 102 with an input end 104 and an output end 106.
- Housing 102 defines a rotation axis R and a transfer tube bushing 108 with a coolant supply aperture disposed centrally and along rotation axis R.
- Transfer tube bushing 108 is configured to seat an oil transfer tube 208 (shown in Fig. 7 ) for receiving a coolant flow within housing 102, such as from a lubrication circuit 206 (also shown in Fig. 7 ) of a gas turbine engine.
- the coolant like lubricant (e.g. oil), enters input end 104, traverses components disposed within housing 102, and exits housing 102 through output end 106.
- lubricant e.g. oil
- Input end 104 may include a plurality of alternating current (AC) electrical power input leads, and as illustrated includes a first AC terminal 110, a second AC terminal 112, and a third AC terminal 114.
- Output end 106 may include a positive direct current (DC) lead 116 and a negative DC lead 118 (shown in Fig. 2 ).
- DC direct current
- Rectifier circuit 120 is disposed within an interior of housing 102 and includes a plurality of diodes and diode plates arranged along rotation axis R of rectifier 100. As illustrated, rectifier 100 includes five bus bars, six diodes, eight diode plates, and a resistor electrically connected with one another to form rectifier circuit 120. Each of the six diodes includes axially opposed anode and cathode faces, indicated with positive and negative symbols in Fig. 2 , and which are coaxial with one another and angled relative to rotation axis R.
- the five bus bars of rectifier circuit 120 include three AC bus bars, each carrying separate AC phases, and two DC bus bars.
- rectifier 100 includes a first AC bus bar 134 connected to first AC terminal 110, a second AC bus bar 136 connected to second AC terminal 112, and a third AC bus bar 138 connected to third AC terminal 114.
- Rectifier 100 also includes a positive DC bus bar 140 connected to positive DC terminal 116 and a negative DC bus bar 142 connected to negative DC terminal 118.
- the six diodes of rectifier circuit 120 include a first diode 122, a second diode 124, a third diode 126, a fourth diode 128, a fifth diode 130, and a sixth diode 132.
- Each of the six diodes is electrically interconnected with one another within a rectification circuit between one of the plurality of bus bars, i.e. first AC bus bar 134, second AC bus bar 136, third AC bus bar 138, positive DC bus bar 140, and negative bus bar 142, for rectifying AC electrical power received at the AC terminals, i.e. first AC terminal 110, second AC terminal 112, and third AC terminal 114, into DC electrical power.
- the rectification circuit thereafter provides the DC electrical power to positive DC terminal 116 and negative DC terminal 118 for on-rotor use.
- the eight diode plates of rectifier circuit 120 include a first diode plate 144, a second diode plate 146, a third diode plate 148, a fourth diode plate 150, a fifth diode plate 152, a sixth diode plate 154, a seventh diode plate 155, and an eighth diode plate 156.
- First diode plate 144 electrically connects an anode face of first diode 122 with positive DC us bar 140.
- Second diode plate 146 is disposed between first diode 122 and second diode 124, and electrically interconnects both a cathode face of first diode 122 and an anode face of second diode 124 with first AC bus bar 134.
- Third diode plate 148 is disposed between second diode 124 and third diode 126, and electrically interconnects both a cathode face of second diode 124 and a cathode face of third diode 126 with negative DC bus bar 142.
- Fourth diode plate 150 is disposed between third diode 126 and fourth diode 128, and electrically interconnects both an anode face of third diode 126 and a cathode face of fourth diode 128 with second AC bus bar 136.
- Fifth diode plate 152 is disposed between fourth diode 128 and fifth diode 130, and electrically interconnects both an anode face of fourth diode 128 and an anode face of fifth diode 130 with positive DC bus bar 140.
- Sixth diode plate 154 is disposed between fifth diode 130 and sixth diode 132, and electrically interconnects both a cathode face of fifth diode 130 and an anode face of sixth diode 132 with third AC bus bar 138.
- a resistor 158 electrically connected in series with a seventh diode plate 155 connects a cathode face of sixth diode 132 with negative DC bus bar 142 and eighth diode plate 156 connects resistor 158 with positive DC bus bar 140.
- rectifier circuit 120 generates heat while rectifying input AC electrical power into DC electrical power.
- a generator e.g. generator 200 (shown in Fig. 7 ) provides a flow of coolant to rectifier 100 for purposes of cooling rectifier circuit 120 while rectifying AC electrical power into DC electrical power.
- coolant provided to generator 200 enters rectifier 100 through a coolant aperture defined by transfer tube bushing 108 (shown in Fig. 1 ), flows across surfaces of the plurality of diodes and other components disposed within housing 102, and exits housing 102 through output end 106.
- transfer tube bushing 108 shown in Fig. 1
- Fluids with low electrical conductivity such as certain types of lubricants and oils, can acquire a space charge as the fluid flows across a solid surface due to the frictional charge separation that occurs at the liquid-solid interface.
- the space charge developed can be transported by the fluid flow, forming a streaming current in the liquid flow.
- Lubricant filters for example, can be sources of streaming charge generation due to the shearing action that occurs within the filter.
- this flow electrification process can cause electrostatic charge to accumulate and potentially generate electrostatic surface potential at liquid-solid interfaces of magnitude sufficient to damage the electrical structure(s) during a discharge event.
- charge accumulation can exceed the rotor circuit dielectric capability, and discharge can occurs.
- the capacitive effects of the rotor circuit insulation can produce a large reverse bias across the diodes, potentially causing the diode to fail.
- Rectifier 100 is electrically grounded, thereby limiting electrostatic charge accumulation to below levels where discharge events can potentially damage circuit components.
- rectifier 100 includes a transfer tube bushing 108 that electrically connects to positive DC bus bar 140. The electrical connection grounds rectifier circuit 120 through transfer tube bushing 108 and positive DC bus bar 140, thereby providing a path for accumulated electrostatic charge to ground, and enables control of electrostatic discharge events. This prevents electrostatic of discharge of magnitude sufficient to damage components of rectifier circuit 120, such as could otherwise be possible - particularly following an engine lubricant change where static charge accumulation can be significant. Examples of suitable grounding schemes can be found in U.S. Patent No. 8,063,522 .
- Each diode includes an anode face A and a cathode face C.
- Anode face A and cathode face C are each angled with respect to rotation axis R, and as illustrated are angled at about a 90-degree angle relative to rotation axis R.
- suitable diodes are dual-face diodes sold under the trade name PowerEx ® , and are available from PowerEx, Inc. of Youngwood, Pennsylvania.
- Each diode plate, i.e. diode plates 144-156 includes a plate-like body B and an axially-extending key D. Please-like body B overlays the face of axially adjacent diode(s), and key D provides electrical connectivity to one of the AC or DC bus bars, i.e. bus bars 134-144.
- rectifier 100 is shown in cross-section.
- Key D of first diode plate 144 has an axial length 170 that is greater than an axial height 172 of first diode 122.
- First diode plate 144 also axially overlaps second diode plate 146.
- Second diode plate 146 is rotationally offset relative to rotation axis such that first diode plate 144 is nested with second diode plate 146, thereby providing an axially compact structure.
- the axially compact structure provided by the nested arrangement of the diode plates and intervening diode reduces the contact area between the diode and lubricant flowing through rectifier 100, reducing the amount of surface area exposed to the static charge-carrying lubricant.
- first diode plate 144 also axially overlaps and nests with third diode plate 148.
- rectifier 100 includes six diodes (122-132), eight diode plates (144-156), a plurality of diode retainers 184, and a diode pivot 176.
- the diodes, i.e. diodes 122-132, are each axially stacked in relation to one another.
- Respective diode retainers 184 circumferentially surround each diode between respective pairs of axially adjacent diode plates.
- the diode plates, i.e. diode plates 144-156 are axially stacked with one another and nested with one another such that seven of the diode plates overlap and nest with one another.
- Diode plates 144-156 are also circumferentially clocked with respect to one another about rotation axis R such that each diode plate both is electrically connected with a bus bars and nests with an axially adjacent diode plate.
- Diode pivot 176 is an electrically passive component, and can therefore be lengthened or shortened in relation to housing 102 such that housing 102 can fit into rotor assembly 200 (shown in Fig;. 7 ) without altering the shape of the cavity seating rectifier 100. This can be done, for example, by increasing an axial length of either or both of diode pivot 176 and resistor 158, and without modifying rotor assembly 200.
- diode retainer 184 includes a retainer body 194.
- Retainer body 194 defines a central aperture 186 for seating a diode, a keyway 188 for seating and circumferentially locking a diode plate, and a plurality of flow apertures 190.
- Central aperture 186 is bounded by a plurality of circumferentially adjacent diode surfaces 192 for fixing a diode within diode retainer 184.
- Flow apertures 190 include suitably sized flow apertures for allowing coolant to flow through rectifier 100 (shown in Fig. 1 ), along rotation axis R (shown in Fig. 1 ), and off-axis for purposes of cooling diodes disposed therein.
- Barrier wall 196 is adjacent to keyway 188 and electrically insulates the diode plates from one another in the radial direction.
- first end 104 is shown with oil transfer tube bushing 108 removed.
- First diode plate 144 is clocked relative to second diode plate 146 by a radially extending wedge profile of barrier wall 196.
- the width of barrier wall 196 at its radially inner end defines the electrical clearance between first diode plate 144 and second diode plate 146, physically separating first diode plate 144 from second diode plate 146 such that each is electrically isolated from one another within a predetermined potential difference limit. This prevents internal shorting within rectifier 100.
- Generator 200 includes a rotor assembly 202 rotatably disposed in relation to a stator assembly 204.
- Rotor assembly 202 includes a hollow shaft 212 that seats within its interior rectifier 100 having a diode pack as described above.
- Stator assembly 204 includes a lubrication circuit 206 that is in fluid communication rectifier 100 and the rectifier diode pack through an oil transfer tube 208.
- Transfer tube 208 seats within transfer tube bushing 108, is rotatable relative transfer tube bushing 108, and is configured to a flow of lubricant from lubrication circuit 206 through oil transfer tube 208 for purposes of cooling the diode pack disposed within rectifier 100.
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Description
- The present disclosure relates to electrical machines, and more particularly to synchronous machines like electrical machine generators.
- Direct drive generators and integrated drive generators are commonly used of aircraft to convert mechanical energy into electrical power. Direct drive generators are generally connected to an aircraft engine directly, without a gearbox or transmission assembly, and may supply variable frequency alternating current (AC) electrical power to an aircraft. Integrated drive generators typically connect to aircraft engine through a continuously variable transmission such as a constant speed drive. The continuously variable transmission receives rotational energy from the engine having a variable speed, converts the variable speed rotational energy into constant speed rotational energy, and applies the constant speed rotational energy to the integrated drive generator, the integrated drive generator thereby producing constant frequency AC electrical power. Both direct drive generators and integrated drive generators may include a diode pack operatively associated with a rotor of the generator assembly.
- Such conventional diode pack devices, rectifier systems, and methods of making and using such devices and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved diode packs. The present disclosure provides a solution for this need. Patent document
US 4,628,219 discloses a rectifier. - A rectifier includes a diode with an anode face and an opposed cathode face that are both angled in relation to a rotation axis of the diode. A first diode plate overlays the diode anode face. A second diode plate overlays the diode cathode face. The first and second diode plates are nested with one another such that portions of the diode plates axially overlap one another along a length of the diode rotation axis. Each diode plate includes a body angled with respect to the rotation axis and having an axially extending key segment. The key segment having an axial length that is greater than an axial height of the diode. In certain embodiments, an oil transfer tube bushing can be axially disposed along the rotation axis. An end of the oil transfer tube bushing can be electrically connected to the diode through the first diode for grounding the diode through the oil transfer tube bushing. The key segments can be rotationally offset from one another about the rotation axis.
- In accordance with certain embodiments, a diode retainer can be axially disposed between the first and second diode plates such that the diode retainer circumferentially surrounds the diode. The diode retainer can define a keyway on its outer periphery, and a key segment of the second diode plate can seat in the diode retainer keyway. The diode retainer can define barrier walls adjacent to the keyway that electrically insulate the diode plates from one another in the radial direction. The diode retainer can define a central diode aperture bounded by a plurality of diode surfaces such that the diode and diode retainer share a common axial position. The diode retainer can define a plurality of flow apertures that bound the central diode aperture. Circumferentially adjacent flow apertures can be separated by one of the diode surfaces.
- It is also contemplated that, in accordance with certain embodiments, the diode can be a first diode, and the rectifier can include a plurality of such diodes, for example six diodes, axially stacked in relation to one another. The rectifier can also include a plurality of diode plates, for example five diode plates, and each of the diode plates can be axially stacked between axially adjacent diodes and nested with an axially adjacent diode plate. The diodes and diode plates can form a diode pack with an axial length, and the rectifier can further include a diode pivot extending along the rotation axis and having an axial length greater than the length of the diode pack.
- A generator includes a rotor shaft with a rectifier cavity, a rectifier as described above seated in the rectifier cavity, and a transfer tube in fluid communication with the rectifier. The rotor shaft is rotatable about the rectifier rotation axis. The transfer tube extends axially along the rotation axis and is connected electrically to the rectifier through the first diode plate.
- In embodiments, the rectifier can include a transfer tube bushing seated between the first diode plate and the transfer tube. The transfer tube bushing can be fixed relative to the first diode plate and rotatable relative to the transfer tube for grounding the rectifier with the rotor shaft.
- From another aspect, also disclosed herein is a generator, comprising a rotor shaft defining a rotation axis, a rectifier circuit fixed in relation to the rotor shaft, including a diode with anode and cathode faces angled relative to the rotation axis, a first diode plate overlaying the anode face of the diode, and a second diode plate overlaying the cathode face of the diode. The first and second diode plates are nested with one another such that portions of the first and second diode plates axially overlap along the rotation axis. An oil transfer tube extends along the rotation axis and is electrically connected to the first diode plate, and an oil transfer tube bushing is coupled between the first diode plate and the oil transfer tube. The oil transfer tube bushing is fixed in relation to the first diode plate and rotatable in relation to the oil transfer tube for grounding the diode through the rotor shaft.
- These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
- So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
-
Fig. 1 is a perspective view of an exemplary embodiment of a rotating rectifier constructed in accordance with the present disclosure, showing input and output current leads; -
Fig. 2 is a schematic view of the rotating rectifier ofFig. 1 , showing a circuit diagram of elements disposed within an interior of the rectifier; -
Fig. 3 is an exploded perspective view of the rotating rectifier ofFig. 1 , showing axially stacked diodes disposed between nested diode plates; -
Fig. 4 is a cross-sectional elevation of the rotating rectifier ofFig. 1 , showing the axial height of the axially stacked diodes and nested diode plates; -
Fig. 5 includes top and bottom perspective views of a diode retainer for the rotating rectifier ofFig. 1 , showing coolant passages and diode walls of the diode retainer; -
Fig. 6 is a partial perspective end view of the rotating rectifier ofFig. 1 , showing an electrical clearance defined between axially adjacent and nested diode plates; and -
Fig. 7 is a cross-sectional side elevation of a generator including the rectifier ofFig. 1 , showing the rotating rectifier seated within a rotor shaft and in fluid communication with a lubrication circuit of the generator. - Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a rectifier in accordance with the disclosure is shown in
Fig. 1 and is designated generally byreference character 100. Other embodiments of rectifiers in accordance with the disclosure, or aspects thereof, are provided inFigs. 2-7 , as will be described. The systems and methods described herein can be for electrical generators, such as aircraft main engine and auxiliary power unit generators. - Rectifier 100 includes a
housing 102 with aninput end 104 and anoutput end 106.Housing 102 defines a rotation axis R and atransfer tube bushing 108 with a coolant supply aperture disposed centrally and along rotation axis R.Transfer tube bushing 108 is configured to seat an oil transfer tube 208 (shown inFig. 7 ) for receiving a coolant flow withinhousing 102, such as from a lubrication circuit 206 (also shown inFig. 7 ) of a gas turbine engine. In this respect the coolant, like lubricant (e.g. oil), entersinput end 104, traverses components disposed withinhousing 102, and exits housing 102 throughoutput end 106.Input end 104 may include a plurality of alternating current (AC) electrical power input leads, and as illustrated includes afirst AC terminal 110, asecond AC terminal 112, and athird AC terminal 114.Output end 106 may include a positive direct current (DC)lead 116 and a negative DC lead 118 (shown inFig. 2 ). - With reference to
Fig. 2 , arectifier circuit 120 is shown.Rectifier circuit 120 is disposed within an interior ofhousing 102 and includes a plurality of diodes and diode plates arranged along rotation axis R ofrectifier 100. As illustrated,rectifier 100 includes five bus bars, six diodes, eight diode plates, and a resistor electrically connected with one another to formrectifier circuit 120. Each of the six diodes includes axially opposed anode and cathode faces, indicated with positive and negative symbols inFig. 2 , and which are coaxial with one another and angled relative to rotation axis R. - The five bus bars of
rectifier circuit 120 include three AC bus bars, each carrying separate AC phases, and two DC bus bars. In thisrespect rectifier 100 includes a firstAC bus bar 134 connected tofirst AC terminal 110, a secondAC bus bar 136 connected tosecond AC terminal 112, and a thirdAC bus bar 138 connected tothird AC terminal 114.Rectifier 100 also includes a positiveDC bus bar 140 connected to positive DC terminal 116 and a negativeDC bus bar 142 connected tonegative DC terminal 118. - The six diodes of
rectifier circuit 120 include afirst diode 122, asecond diode 124, athird diode 126, afourth diode 128, afifth diode 130, and asixth diode 132. Each of the six diodes is electrically interconnected with one another within a rectification circuit between one of the plurality of bus bars, i.e. firstAC bus bar 134, secondAC bus bar 136, thirdAC bus bar 138, positiveDC bus bar 140, andnegative bus bar 142, for rectifying AC electrical power received at the AC terminals, i.e.first AC terminal 110,second AC terminal 112, andthird AC terminal 114, into DC electrical power. The rectification circuit thereafter provides the DC electrical power to positive DC terminal 116 and negative DC terminal 118 for on-rotor use. - The eight diode plates of
rectifier circuit 120 include afirst diode plate 144, asecond diode plate 146, athird diode plate 148, afourth diode plate 150, afifth diode plate 152, asixth diode plate 154, aseventh diode plate 155, and aneighth diode plate 156.First diode plate 144 electrically connects an anode face offirst diode 122 with positive DC us bar 140.Second diode plate 146 is disposed betweenfirst diode 122 andsecond diode 124, and electrically interconnects both a cathode face offirst diode 122 and an anode face ofsecond diode 124 with firstAC bus bar 134.Third diode plate 148 is disposed betweensecond diode 124 andthird diode 126, and electrically interconnects both a cathode face ofsecond diode 124 and a cathode face ofthird diode 126 with negativeDC bus bar 142.Fourth diode plate 150 is disposed betweenthird diode 126 andfourth diode 128, and electrically interconnects both an anode face ofthird diode 126 and a cathode face offourth diode 128 with secondAC bus bar 136.Fifth diode plate 152 is disposed betweenfourth diode 128 andfifth diode 130, and electrically interconnects both an anode face offourth diode 128 and an anode face offifth diode 130 with positiveDC bus bar 140.Sixth diode plate 154 is disposed betweenfifth diode 130 andsixth diode 132, and electrically interconnects both a cathode face offifth diode 130 and an anode face ofsixth diode 132 with thirdAC bus bar 138. Aresistor 158 electrically connected in series with aseventh diode plate 155 connects a cathode face ofsixth diode 132 with negativeDC bus bar 142 andeighth diode plate 156 connectsresistor 158 with positiveDC bus bar 140. - As will be appreciated,
rectifier circuit 120 generates heat while rectifying input AC electrical power into DC electrical power. A generator, e.g. generator 200 (shown inFig. 7 ), provides a flow of coolant to rectifier 100 for purposes of coolingrectifier circuit 120 while rectifying AC electrical power into DC electrical power. In this respect coolant provided togenerator 200 entersrectifier 100 through a coolant aperture defined by transfer tube bushing 108 (shown inFig. 1 ), flows across surfaces of the plurality of diodes and other components disposed withinhousing 102, and exitshousing 102 throughoutput end 106. As the coolant traversesrectifier circuit 120, heat transfers from the plurality of diodes to the coolant. This keeps the diodes within a predetermined temperature range during operation, the temperature range being determined by the intended application ofrectifier 100. - One challenge to flowing coolant across electrical structures like diodes is that electrostatic charge can accumulate on the structures from the coolant flowing across the structures. Fluids with low electrical conductivity, such as certain types of lubricants and oils, can acquire a space charge as the fluid flows across a solid surface due to the frictional charge separation that occurs at the liquid-solid interface. The space charge developed can be transported by the fluid flow, forming a streaming current in the liquid flow. Lubricant filters, for example, can be sources of streaming charge generation due to the shearing action that occurs within the filter. If the walls bounding the flow system are electrically insulated or have a floating potential, this flow electrification process can cause electrostatic charge to accumulate and potentially generate electrostatic surface potential at liquid-solid interfaces of magnitude sufficient to damage the electrical structure(s) during a discharge event. In the case of lubricant streaming charge with a rotating rectifier, charge accumulation can exceed the rotor circuit dielectric capability, and discharge can occurs. At discharge, the capacitive effects of the rotor circuit insulation can produce a large reverse bias across the diodes, potentially causing the diode to fail.
-
Rectifier 100 is electrically grounded, thereby limiting electrostatic charge accumulation to below levels where discharge events can potentially damage circuit components. In thisrespect rectifier 100 includes atransfer tube bushing 108 that electrically connects to positiveDC bus bar 140. The electrical connectiongrounds rectifier circuit 120 throughtransfer tube bushing 108 and positiveDC bus bar 140, thereby providing a path for accumulated electrostatic charge to ground, and enables control of electrostatic discharge events. This prevents electrostatic of discharge of magnitude sufficient to damage components ofrectifier circuit 120, such as could otherwise be possible - particularly following an engine lubricant change where static charge accumulation can be significant. Examples of suitable grounding schemes can be found inU.S. Patent No. 8,063,522 . - With reference to
Fig. 3 ,rectifier 100 is shown in an exploded perspective view. Each diode includes an anode face A and a cathode face C. Anode face A and cathode face C are each angled with respect to rotation axis R, and as illustrated are angled at about a 90-degree angle relative to rotation axis R. Examples of suitable diodes are dual-face diodes sold under the trade name PowerEx®, and are available from PowerEx, Inc. of Youngwood, Pennsylvania. Each diode plate, i.e. diode plates 144-156, includes a plate-like body B and an axially-extending key D. Please-like body B overlays the face of axially adjacent diode(s), and key D provides electrical connectivity to one of the AC or DC bus bars, i.e. bus bars 134-144. - With reference to
Fig. 4 ,rectifier 100 is shown in cross-section. Key D offirst diode plate 144 has anaxial length 170 that is greater than anaxial height 172 offirst diode 122.First diode plate 144 also axially overlapssecond diode plate 146.Second diode plate 146 is rotationally offset relative to rotation axis such thatfirst diode plate 144 is nested withsecond diode plate 146, thereby providing an axially compact structure. The axially compact structure provided by the nested arrangement of the diode plates and intervening diode reduces the contact area between the diode and lubricant flowing throughrectifier 100, reducing the amount of surface area exposed to the static charge-carrying lubricant. This improves the durability of the diode circuit by reducing the rate at which static charge transfers to the surfaces of the diode devices incorporated in the circuit. As illustrated,first diode plate 144 also axially overlaps and nests withthird diode plate 148. - As illustrated in
Fig. 3 ,rectifier 100 includes six diodes (122-132), eight diode plates (144-156), a plurality ofdiode retainers 184, and adiode pivot 176. The diodes, i.e. diodes 122-132, are each axially stacked in relation to one another.Respective diode retainers 184 circumferentially surround each diode between respective pairs of axially adjacent diode plates. The diode plates, i.e. diode plates 144-156, are axially stacked with one another and nested with one another such that seven of the diode plates overlap and nest with one another. Diode plates 144-156 are also circumferentially clocked with respect to one another about rotation axis R such that each diode plate both is electrically connected with a bus bars and nests with an axially adjacent diode plate. - With continuing reference to
Fig. 4 , axially stacking the diodes between nested diode plates allows diode pack to have anaxial height 180 that is shorter than anaxial length 182 ofdiode pivot 176.Diode pivot 176 is an electrically passive component, and can therefore be lengthened or shortened in relation tohousing 102 such thathousing 102 can fit into rotor assembly 200 (shown inFig;. 7 ) without altering the shape of thecavity seating rectifier 100. This can be done, for example, by increasing an axial length of either or both ofdiode pivot 176 andresistor 158, and without modifyingrotor assembly 200. - With reference to
Fig. 5 ,diode retainer 184 is shown.Diode retainer 184 includes aretainer body 194.Retainer body 194 defines acentral aperture 186 for seating a diode, akeyway 188 for seating and circumferentially locking a diode plate, and a plurality offlow apertures 190.Central aperture 186 is bounded by a plurality of circumferentially adjacent diode surfaces 192 for fixing a diode withindiode retainer 184.Flow apertures 190 include suitably sized flow apertures for allowing coolant to flow through rectifier 100 (shown inFig. 1 ), along rotation axis R (shown inFig. 1 ), and off-axis for purposes of cooling diodes disposed therein.Barrier wall 196 is adjacent to keyway 188 and electrically insulates the diode plates from one another in the radial direction. - With reference to
Fig. 6 ,first end 104 is shown with oiltransfer tube bushing 108 removed.First diode plate 144 is clocked relative tosecond diode plate 146 by a radially extending wedge profile ofbarrier wall 196. The width ofbarrier wall 196 at its radially inner end defines the electrical clearance betweenfirst diode plate 144 andsecond diode plate 146, physically separatingfirst diode plate 144 fromsecond diode plate 146 such that each is electrically isolated from one another within a predetermined potential difference limit. This prevents internal shorting withinrectifier 100. - With reference to
Fig. 7 , agenerator 200 is shown.Generator 200 includes arotor assembly 202 rotatably disposed in relation to astator assembly 204.Rotor assembly 202 includes ahollow shaft 212 that seats within itsinterior rectifier 100 having a diode pack as described above.Stator assembly 204 includes alubrication circuit 206 that is influid communication rectifier 100 and the rectifier diode pack through anoil transfer tube 208.Transfer tube 208 seats withintransfer tube bushing 108, is rotatable relativetransfer tube bushing 108, and is configured to a flow of lubricant fromlubrication circuit 206 throughoil transfer tube 208 for purposes of cooling the diode pack disposed withinrectifier 100. - While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.
Claims (14)
- A rectifier (100), comprising:a diode (122, 124, 126, 128, 130, 132) with opposed anode and cathode faces angled relative to a rotation axis (R);a first diode plate (144, 146, 148, 150, 152, 154, 155, 156) overlaying the anode face of the diode (122 ... 132); anda second diode plate (144 ... 156) overlaying the cathode face of the diode (122 ... 132), wherein the first diode plate (144 ... 156) and second diode plate (144 ... 156) are nested within one another such that portions of the first and second diode plates (144 ... 156) axially overlap along the rotation axis (R); characterised in that each of the diode plates (144 ... 156) further comprises an axially stacked body (B) with an axially extending key segment (D), the key segment (D) having an axial length (170) that is greater than an axial height (172) of the diode (122 ... 132).
- A rectifier as recited in claim 1, further including an oil transfer tube bushing (108) extending along the rotation axis (R), wherein an end of the oil transfer tube bushing (108) is electrically connected to the first diode plate (144 ... 156) for grounding the diode (122 ... 132) through the oil transfer tube bushing (108).
- A rectifier as recited in claim 1, wherein diode key segments (D) are rotationally offset from one another about the rotation axis (R).
- A rectifier as recited in any preceding claim, further including a diode retainer (184) disposed between the first and second diode plates (144 ... 156), wherein the diode retainer (184) circumferentially surrounds the diode (122 ... 132).
- A rectifier as recited in claim 4, wherein a periphery of the diode retainer (184) defines a keyway (188), wherein the key segment (D) of the first diode plate (144 ... 156) seats in the diode retainer keyway (188).
- A rectifier as recited in claim 5, where the diode retainer keyway (188) defines barrier walls (196), wherein the first diode plate (144 ... 156) is electrically insulated from the second diode plate (144 ... 156).
- A rectifier as recited in claim 4, 5 or 6, wherein the diode retainer (184) defines a central diode aperture (186), the diode aperture (186) being bounded by a plurality of diode surfaces (192).
- A rectifier as recited in claim 7, wherein the diode retainer (184) defines a plurality of flow passages (190), the flow passages (190) bounding the central diode aperture (186) and being circumferentially separated by a diode surface (192).
- A rectifier as recited in any preceding claim, wherein the diode (122 ... 132) is a first diode (122), and further including a plurality of diodes (124, 126, 128, 130, 132) axially stacked in relation to the first diode (122).
- A rectifier as recited in claim 9, wherein the plurality of diodes (124 ... 132) includes six diodes electrically connected in a rectifier circuit (120).
- A rectifier as recited in claim 9 or 10, further including a plurality of diode plates (144 ... 156), wherein each of the diode plates (144 ... 156) is axially stacked between adjacent diodes (122 ... 132) and nested with an adjacent diode plate (144 ... 156).
- A rectifier as recited in claim 11, wherein the plurality of diode plates (144 ... 156) includes five diode plates (144 ... 156).
- A rectifier as recited in claim 11 or 12, wherein the diodes (122 ... 132) and diode plates (144 ... 156) form a diode pack with an axial length (180), and further including a diode pivot (176) extending along the rotation axis (R) and having an axial length (182) greater than the diode pack.
- A generator (200), comprising:a rotor shaft (212) defining a rotation axis (R);the rectifier circuit (100) of any preceding claim fixed in relation to the rotor shaft (212):an oil transfer tube (208) extending along the rotation axis (R) and electrically connected to the first diode plate (144 ... 156); andan/the oil transfer tube bushing (108) coupled between the first diode plate (144 ... 156) and oil transfer tube (208), wherein the oil transfer tube bushing (108) is fixed in relation to the first diode plate (144 ... 156) and rotatable in relation to the oil transfer tube (208) for grounding the diode (122 ... 132) through the rotor shaft (212).
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US14/611,971 US9912213B2 (en) | 2015-02-02 | 2015-02-02 | Rotating rectifiers with nested diodes |
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EP3051673A1 EP3051673A1 (en) | 2016-08-03 |
EP3051673B1 true EP3051673B1 (en) | 2017-08-23 |
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EP16153948.1A Active EP3051673B1 (en) | 2015-02-02 | 2016-02-02 | Rotating rectifiers with nested diodes |
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US11764648B2 (en) * | 2020-12-07 | 2023-09-19 | Hamilton Sundstrand Corporation | Rotating rectifiers |
US12009126B2 (en) | 2021-03-13 | 2024-06-11 | Hamilton Sundstrand Corporation | Resistor support assembly with spring seat |
US11949294B2 (en) | 2021-03-13 | 2024-04-02 | Hamilton Sundstrand Corporation | Resistor plate assembly with contact bands |
US11799391B2 (en) * | 2021-03-13 | 2023-10-24 | Hamilton Sundstrand Corporation | Diode mounting ring with contact band inserts |
CN113489346B (en) * | 2021-06-09 | 2022-06-14 | ä¸å›½ç§‘å¦é™¢ç”µå·¥ç ”究所 | Rotary rectifier suitable for high-speed heavy current |
Family Cites Families (8)
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US4745315A (en) | 1983-12-15 | 1988-05-17 | General Electric Company | Brushless exciter with zero-gravity rectifier assembly |
US4603344A (en) * | 1984-07-30 | 1986-07-29 | Sundstrand Corporation | Rotating rectifier assembly |
US4628219A (en) * | 1985-09-13 | 1986-12-09 | Sundstrand Corporation | Rectifier assembly for mounting in a rotor |
US4621210A (en) | 1985-11-22 | 1986-11-04 | Sundstrand Corporation | Electric generator cooling arrangement |
US4827165A (en) * | 1987-11-16 | 1989-05-02 | Sundstrand Corporation | Integrated diode package |
US5065484A (en) | 1989-04-14 | 1991-11-19 | Sundstrand Corporation | Rotating rectifier assembly |
US5796196A (en) * | 1996-08-26 | 1998-08-18 | Sundstrand Corporation | Adaptable rotating rectifier and suppression resistor assembly for two-pole, wound rotor of dynamoelectric machine |
US8063522B2 (en) | 2009-09-14 | 2011-11-22 | Hamilton Sundstrand Corporation | Generator rotor ground bushing |
-
2015
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2016
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US9912213B2 (en) | 2018-03-06 |
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